Alignment and Retention System for Laterally Slideably Engageable Mating Components

ABSTRACT

An elastically averaged alignment system includes a first component having first and second alignment features, and a second component having third and fourth elastically deformable alignment elements. The first and second components are laterally slidably engageable with each other. The third elastically deformable alignment element is configured and disposed to interferingly, deformably and matingly engage with the first alignment feature. The fourth elastically deformable alignment element is configured and disposed to interferingly, deformably and matingly engage with the second alignment feature. Portions of the third and fourth elastically deformable alignment elements when engaged with respective ones of the first and second alignment features elastically deform to an elastically averaged final configuration that aligns the first component relative to the second component in six planar orthogonal directions by averaging the elastic deformation of the respective elastically deformable alignment elements.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application Ser. No. 61/974,107, filed Apr. 2, 2014, which is incorporated herein by reference in its entirety.

FIELD OF THE INVENTION

The subject invention relates to the art of alignment systems, more particularly to an elastically averaged alignment system, and even more particularly to an elastically averaged alignment system providing six-way alignment of laterally slideably engageable mating components on which the alignment system is incorporated.

BACKGROUND

Currently, components, particularly vehicular components such as those found in automotive vehicles, which are to be mated together in a manufacturing process are mutually located with respect to each other by alignment features that are oversized and/or undersized to provide spacing to freely move the components relative to one another to align them without creating an interference therebetween that would hinder the manufacturing process. One example includes two-way and/or four-way male alignment features, typically upstanding bosses, which are received into corresponding female alignment features, typically apertures in the form of holes or slots. There is a clearance between the male alignment features and their respective female alignment features which is predetermined to match anticipated size and positional variation tolerances of the male and female alignment features as a result of manufacturing (or fabrication) variances. As a result, significant positional variation can occur between the mated first and second components having the aforementioned alignment features, which may contribute to the presence of undesirably large variation in their alignment, particularly with regard to the gaps and spacing between them. In the case where these misaligned components are also part of another assembly, such misalignments can also affect the function and/or aesthetic appearance of the entire assembly. Regardless of whether such misalignment is limited to two components or an entire assembly, it can negatively affect function and result in a perception of poor quality.

Accordingly, the art of alignment systems can be enhanced by providing an alignment and retention system or mechanism that can ensure precise two-way, four-way or six-way alignment and fastening of two components via elastic averaging of a plurality elastically deformable alignment and retention elements disposed in mating engagement with a plurality of corresponding alignment features.

SUMMARY OF THE INVENTION

In one exemplary embodiment of the invention, an elastically averaged alignment system includes a first component and a second component. The first component includes at least one of a first alignment feature fixedly disposed with respect to the first component, and at least one of a second alignment feature fixedly disposed with respect to the first component. The second component includes at least one of a third elastically deformable alignment element fixedly disposed with respect to the second component, and at least one of a fourth elastically deformable alignment element fixedly disposed with respect to the second component. The first and second components are laterally slidably engageable with each other. A respective one of the third elastically deformable alignment element is configured and disposed to interferingly, deformably and matingly engage with a respective one of the first alignment feature. A respective one of the fourth elastically deformable alignment element is configured and disposed to interferingly, deformably and matingly engage with a respective one of the second alignment feature. Portions of the third and fourth elastically deformable alignment elements when engaged with respective ones of the first and second alignment features elastically deform to an elastically averaged final configuration that aligns the first component relative to the second component in six planar orthogonal directions by averaging the elastic deformation of the respective elastically deformable alignment elements.

The above features and advantages and other features and advantages of the invention are readily apparent from the following detailed description of the invention when taken in connection with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

Other features, advantages and details appear, by way of example only, in the following detailed description of embodiments, the detailed description referring to the drawings in which:

FIG. 1 depicts an assembly of a first component aligned and retained relative to a second component via an elastically averaged alignment and retention system, in accordance with an embodiment of the invention;

FIG. 2 depicts an isometric view of the first component of FIG. 1 with a mating side of the first component visible, in accordance with an embodiment of the invention;

FIG. 3 depicts an isometric view of the second component of FIG. 1 with a mating side of the second component visible, in accordance with an embodiment of the invention;

FIG. 4 depicts an expanded isometric view of an alignment feature of the first component, in accordance with an embodiment of the invention;

FIG. 5 depicts an expanded isometric view of an elastically deformable alignment element of the second component, in accordance with an embodiment of the invention;

FIG. 6 depicts a side view of the elastically deformable alignment element of FIG. 5 elastically, deformably and matingly engaged with the alignment feature of FIG. 4, where the engagement surfaces are depicted overlapping to illustrate an interference fit therebetween, in accordance with an embodiment of the invention;

FIG. 7A depicts a cross section view through a portion of the assembly of FIG. 1, in accordance with an embodiment of the invention;

FIG. 7B depicts an expanded portion of the cross section view of FIG. 7A, in accordance with an embodiment of the invention; and

FIG. 8 depicts a cross section view through another portion of the assembly of FIG. 1, in accordance with an embodiment of the invention.

DESCRIPTION OF THE EMBODIMENTS

The following description is merely exemplary in nature and is not intended to limit the present disclosure, its application or uses. For example, the embodiments shown comprise vehicle components but the alignment system may be used with any suitable components to provide elastic averaging for precision location and alignment of all manner of mating components and component applications, including many industrial, consumer product (e.g., consumer electronics, various appliances and the like), transportation, energy and aerospace applications, and particularly including many other types of vehicular components and applications, such as various interior, exterior and under hood vehicular components and applications. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features.

As used herein, the term “elastically deformable” refers to components, or portions of components, including component features, comprising materials having a generally elastic deformation characteristic, wherein the material is configured to undergo a resiliently reversible change in its shape, size, or both, in response to application of a force. The force causing the resiliently reversible or elastic deformation of the material may include a tensile, compressive, shear, bending or torsional force, or various combinations of these forces. The elastically deformable materials may exhibit linear elastic deformation, for example that described according to Hooke's law, or non-linear elastic deformation.

Elastic averaging provides elastic deformation of the interface(s) between mated components, wherein the average deformation provides a precise alignment, the manufacturing positional variance being minimized to X_(min), defined by X_(min)=X/√N, wherein X is the manufacturing positional variance of the locating features of the mated components and N is the number of features inserted. To obtain elastic averaging, an elastically deformable component is configured to have at least one feature and its contact surface(s) that is over-constrained and provides an interference fit with a mating feature of another component and its contact surface(s). The over-constrained condition and interference fit resiliently reversibly (elastically) deforms at least one of the at least one feature or the mating feature, or both features. The resiliently reversible nature of these features of the components allows repeatable insertion and withdrawal of the components that facilitates their assembly and disassembly. In some embodiments, the elastically deformable component configured to have the at least one feature and associated mating feature disclosed herein may require more than one of such features, depending on the requirements of a particular embodiment. Positional variance of the components may result in varying forces being applied over regions of the contact surfaces that are over-constrained and engaged during insertion of the component in an interference condition. It is to be appreciated that a single inserted component may be elastically averaged with respect to a length of the perimeter of the component. The principles of elastic averaging are described in detail in commonly owned, co-pending U.S. patent application Ser. No. 13/187,675, now U.S. Pat. No. 8,695,201, the disclosure of which is incorporated by reference herein in its entirety. The embodiments disclosed above provide the ability to convert an existing component that is not compatible with the above-described elastic averaging principles, or that would be further aided with the inclusion of an elastically averaged alignment and retention system as herein disclosed, to an assembly that does facilitate elastic averaging and the benefits associated therewith.

Any suitable elastically deformable material may be used for the mating components and alignment features disclosed herein and discussed further below, particularly those materials that are elastically deformable when formed into the features described herein. This includes various metals, polymers, ceramics, inorganic materials or glasses, or composites of any of the aforementioned materials, or any other combinations thereof suitable for a purpose disclosed herein. Many composite materials are envisioned, including various filled polymers, including glass, ceramic, metal and inorganic material filled polymers, particularly glass, metal, ceramic, inorganic or carbon fiber filled polymers. Any suitable filler morphology may be employed, including all shapes and sizes of particulates or fibers. More particularly any suitable type of fiber may be used, including continuous and discontinuous fibers, woven and unwoven cloths, felts or tows, or a combination thereof. Any suitable metal may be used, including various grades and alloys of steel, cast iron, aluminum, magnesium or titanium, or composites thereof, or any other combinations thereof. Polymers may include both thermoplastic polymers or thermoset polymers, or composites thereof, or any other combinations thereof, including a wide variety of co-polymers and polymer blends. In one embodiment, a preferred plastic material is one having elastic properties so as to deform elastically without fracture, as for example, a material comprising an acrylonitrile butadiene styrene (ABS) polymer, and more particularly a polycarbonate ABS polymer blend (PC/ABS). The material may be in any form and formed or manufactured by any suitable process, including stamped or formed metal, composite or other sheets, forgings, extruded parts, pressed parts, castings, or molded parts and the like, to include the deformable features described herein. The elastically deformable alignment features and associated component may be formed in any suitable manner. For example, the elastically deformable alignment features and the associated component may be integrally formed, or they may be formed entirely separately and subsequently attached together. When integrally formed, they may be formed as a single part from a plastic injection molding machine, for example. When formed separately, they may be formed from different materials to provide a predetermined elastic response characteristic, for example. The material, or materials, may be selected to provide a predetermined elastic response characteristic of any or all of the elastically deformable alignment features, the associated component, or the mating component. The predetermined elastic response characteristic may include, for example, a predetermined elastic modulus.

As used herein, the term vehicle is not limited to just an automobile, truck, van or sport utility vehicle, but includes any self-propelled, towed, or movable conveyance suitable for transporting or supporting a burden.

In accordance with an example embodiment of the invention, and with reference to FIGS. 1-3, an elastically averaged alignment system 10 includes a first component 100 having at least one of a first alignment feature 102 (individually herein referred to by reference numerals 102.1, 102.2 . . . ) fixedly disposed with respect to the first component 100, or at least one of a second alignment feature 104 (individually herein referred to by reference numerals 104.1, 104.2 . . . ) fixedly disposed with respect to the first component 100, and a second component 200 having at least one of a third elastically deformable alignment element 202 (individually herein referred to by reference numerals 202.1, 202.2 . . . ) fixedly disposed with respect to the second component 200, and at least one of a fourth elastically deformable alignment element 204 (individually herein referred to by reference numerals 204.1, 204.2 . . . ) fixedly disposed with respect to the second component 200. The first and second components 100, 200 are laterally slideably engageable with each other in a manner that will be described in more detail below.

With reference to FIGS. 4-7B (FIG. 7B depicts an expanded view of detail 300 of FIG. 7A) in combination with FIGS. 1-3, respective ones of the third elastically deformable alignment element 202 are configured and disposed to interferingly, deformably and matingly engage with associated respective ones of the first alignment feature 102, and respective ones of the fourth elastically deformable alignment element 204 is configured and disposed to interferingly, deformably and matingly engage with a respective one of the second alignment feature 104. Portions of the third and fourth elastically deformable alignment elements 202, 204 when engaged with respective ones of the first and second alignment features 102, 104 elastically deform to an elastically averaged final configuration that aligns the first component 100 relative to the second component 200 in six planar orthogonal directions, such as the +/−x-direction, the +/−y-direction, and the +/−z-direction of an orthogonal coordinate system (see FIG. 1), for example, which is herein referred to as six-way alignment, by averaging the elastic deformation of the respective elastically deformable alignment elements 202, 204.

As depicted in FIGS. 2 and 3, the elastically averaged alignment system 10 includes an arrangement wherein the first component 100 has more than one of the first and second alignment features 102, 104, and the second component 200 has more than one of the third and fourth elastically deformable alignment elements 202, 204. The more than one of the third and fourth elastically deformable alignment elements 202, 204 are geometrically distributed with respect to respective ones of the more than one first and second alignment features 102, 104, such that portions of the elastically deformable alignment elements of respective ones of the more than one third and fourth elastically deformable alignment elements 202, 204, when engaged with respective ones of the more than one first and second alignment features 102, 104, elastically deform to an elastically averaged final configuration that further aligns the first component 100 relative to the second component 200 in six planar orthogonal directions.

As depicted in FIGS. 2 and 4, the first alignment feature 102 is formed by a projection 106 having a curved cross section that extends off of a first wall 108. In an embodiment, the curved cross section has a wave shape. As depicted in FIG. 2, the first wall 108 is on one side of a linear pocket 110 (individually herein referred to by reference numerals 110.1, 110.2 . . . ) formed in the first component 100, and a second wall 112 opposing the first wall 108 is on an opposite side of the linear pocket 110. The first alignment feature 102 is disposed extending sideways off of the first wall 108, and the second alignment feature 104 forms a portion of the second wall 112.

As depicted in FIGS. 3, 5, 7A and 7B, the third elastically deformable alignment element 202 is formed by a curved projection 206 having a curved cross section that extends sideways off of a first side 208 of a third wall 210 (individually herein referred to by reference numerals 210.1, 210.2 . . . ). In an embodiment, the curved cross section has a crescent shape.

As also depicted in FIGS. 3, 5, 7A and 7B, the fourth elastically deformable alignment element 204 is formed by a distal projection 212 that extends sideways off of a second side 214 of the third wall 210 at a distal end 216 of the third wall 210. The second side 214 of the third wall 210 faces away from the first side 208 of the third wall 210. In an embodiment, the third wall 210 has slots 218 on each side of the distal projection 212, where the slots 218 are open at and extend from the distal end 216 of the third wall 210 toward a proximal end 220 of the third wall 210. The portion of the third wall 210 between the slots 218 and having the distal projection 212 forms a cantilevered section of the third wall 210 that is capable of undergoing elastic deflection in a manner similar to how a cantilevered beam may be deflected at its free end.

In an embodiment, the first and second components 100, 200 are assembled together to arrive at the assembly depicted in FIG. 1 as follows. First, the mating side 224 of the second component 200 (mating side depicted in FIG. 3) is oriented proximate to and in face-to-face relationship with the mating side 116 of the first component (mating side depicted in FIG. 2), but laterally offset such that an inner end 222 (see FIG. 7A) of the third wall 210 of the second component 200 is poised for entry into the open end 114 (see FIG. 2) of the linear pocket 110 of the first component 100. Then, the second component 200 is laterally and slideably engaged with the first component 100 such that the third and fourth elastically deformable alignment elements 202, 204 fully engage with respective ones of the first and second alignment features 102, 104, as depicted in FIGS. 6, 7A and 7B. A ramped surface 226 (see FIG. 7B) on the distal projection 212, along with the curvatures of the first alignment feature 102 and third elastically deformable alignment element 202, facilitates the assembly of the first and second components 100, 200. As depicted in FIGS. 6 and 7B, the first alignment feature 102 and the third elastically deformable alignment element 202 are disposed in an interference fit condition 302 in a first z-direction, and the second alignment feature 104 and the fourth elastically deformable alignment element 204 are disposed in an interference fit condition 304 in a second y-direction orthogonal to the first z-direction, when the first and second components 100, 200 are fully engaged with each other, thereby elastically aligning and restraining the first and second components 100, 200 in the +/−y and +/−z directions. While the engagement surfaces depicted in FIGS. 6, 7A and 7B are depicted overlapping each other to illustrate interference fit conditions 302, 304 (dotted lines depicting the degree of overlap), it will be appreciated that this is for illustration purposes only so as to illustrate an interference fit between the respective parts, and that in actuality the elastically deformable alignment elements 202, 204 will elastically deform by the amount of the interference fit condition shown. For example, the cantilevered crescent shaped end of the third elastically deformable alignment element 202 will tend to flatten out slightly and bend slightly at the cantilevered free end by the amount of the interference fit condition 302, and the cantilevered distal projection 212 of the fourth elastically deformable alignment element 204 will tend to bend slightly at the cantilevered free end by the amount of the interference fit condition 304. Elastic alignment and restraint of the first and second components 100, 200 in the +/−x-directions is achieved by the crescent shaped third elastically deformable alignment element 202 being elastically deformably nestled in a trough of the wave shaped first alignment feature 102.

With reference now to FIG. 8, it can be seen that the first and second components 100, 200 are tightly fit relative to each other by the third elastically deformable alignment element 202 of the second component 200 being interferingly captured under the first alignment feature 102 of the first component 100, which pulls the mating side 224 of the second component 200 snugly against the first wall 108, and therefore snugly against the mating side 116, of the first component 100, with little or no gap therebetween. As depicted in FIG. 8, only an end portion of the crescent shaped cantilevered projection of the third elastically deformable alignment element 202 overlaps the wave shaped projection of the first alignment feature 102, which provides for cantilevered elastic deflection of the third elastically deformable alignment element 202 when engaged with the first alignment feature 102.

With reference now back to FIGS. 2 and 3, an embodiment includes an arrangement where there are two sets of the first and second alignment features 102, 104 (denoted by 102.1, 102.2, 104.1, 104.2) arranged in respective spaced-apart linear pockets 110.1, 110.2, and two sets of the third and fourth elastically deformable alignment elements 202, 204 (denoted by 202.1, 202.2, 204.1, 204.2) arranged on respective spaced-apart linear walls 210.1, 210.2. Like features and elements of the two sets are arranged so that any biasing forces they create between them oppose each other. For example, when elastically, deformably and matingly engaged with each other, the fourth elastically deformable alignment element 204.1 of the first set (toward the left in FIG. 3) is elastically deformed inward thereby creating an outward biasing force on the second alignment feature 104.1 of the first set (toward the left in FIG. 2), and the fourth elastically deformable alignment element 204.2 of the second set (toward the right in FIG. 3) is elastically deformed inward thereby creating an outward biasing force on the second alignment feature 104.2 of the second set (toward the right in FIG. 2), resulting in two outward biasing forces that oppose each other. The same result would be achieved if the placement of the first and second alignment features of the first and second sets, and the corresponding first and second elastically deformable alignment elements of the first and second sets, were switched. As such, the scope of the invention is not limited to only the orientation of features and elements depicted in FIGS. 2 and 3.

In view of all that is disclosed, illustrated, described, and incorporated by reference herein, it will be appreciated that the scope of the invention is not limited to only the use of the herein disclosed elastically deformable alignment elements and the corresponding alignment features, but also encompasses the use of such elements and features in combination with other elastic averaging alignment features, male or female.

When the first component 100 and second component 200 are components of a vehicle, an advantageous assembly results because the clamping force, together with the elastic deformation of the alignment features that has these parts in pressing contact already, reduces the tendency of the components to vibrate or rattle against one another, and thus improves the noise, vibration and harshness (NVH) characteristics of the components and the vehicle in which they are installed. The selective engagement of the elastically deformable alignment elements and the corresponding alignment features also provides a stiffened assembly of the first component 100 and second component 200 when the first and second components are mutually mated to each other, including a stiffness that is greater than that realized by using the alignment features alone, since the clamping force between the first component and second component increases the stiffness of the assembly, for example. In an embodiment, the first component 100 is a hinge portion of a fuel door for a vehicle, and the second component 200 is a cover portion of the fuel door.

While the invention has been described with reference to exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiments disclosed, but that the invention will include all embodiments falling within the scope of the application. 

What is claimed is:
 1. An elastically averaged alignment system, comprising: a first component comprising at least one of a first alignment feature fixedly disposed with respect to the first component, and at least one of a second alignment feature fixedly disposed with respect to the first component; a second component comprising at least one of a third elastically deformable alignment element fixedly disposed with respect to the second component, and at least one of a fourth elastically deformable alignment element fixedly disposed with respect to the second component; wherein the first and second components are laterally slidably engageable with each other; wherein a respective one of the third elastically deformable alignment element is configured and disposed to interferingly, deformably and matingly engage with a respective one of the first alignment feature; wherein a respective one of the fourth elastically deformable alignment element is configured and disposed to interferingly, deformably and matingly engage with a respective one of the second alignment feature; and wherein portions of the third and fourth elastically deformable alignment elements when engaged with respective ones of the first and second alignment features elastically deform to an elastically averaged final configuration that aligns the first component relative to the second component in six planar orthogonal directions by averaging the elastic deformation of the respective elastically deformable alignment elements.
 2. The elastically averaged alignment system of claim 1, wherein the first component comprises more than one of the first and second alignment features, and the second component comprises more than one of the third and fourth elastically deformable alignment elements, the more than one of the third and fourth elastically deformable alignment elements being geometrically distributed with respect to respective ones of the more than one first and second alignment features, such that portions of the elastically deformable alignment elements of respective ones of the more than one third and fourth elastically deformable alignment elements, when engaged with respective ones of the more than one first and second alignment features, elastically deform to an elastically averaged final configuration that further aligns the first component relative to the second component in six planar orthogonal directions.
 3. The elastically averaged alignment system of claim 1, wherein the first alignment feature comprises a projection having a curved cross section that extends off of a first wall.
 4. The elastically averaged alignment system of claim 3, wherein the curved cross section comprises a wave shape.
 5. The elastically averaged alignment system of claim 1, wherein: the first component comprises a pocket having opposing first and second side wall; the first alignment feature is disposed on the first wall; and the second alignment feature is a portion of the second wall.
 6. The elastically averaged alignment system of claim 1, wherein: the third elastically deformable alignment element comprises a curved projection having a curved cross section that extends off of a first side of a third wall.
 7. The elastically averaged alignment system of claim 6, wherein the curved cross section comprises a crescent shape.
 8. The elastically averaged alignment system of claim 6, wherein: the fourth elastically deformable alignment element comprises a distal projection that extends off of a second side of the third wall at a distal end of the third wall, the second side of the third wall facing away from the first side of the third wall.
 9. The elastically averaged alignment system of claim 8, wherein: the third wall comprises slots on each side of the distal projection, the slots extending from the distal end of the third wall toward a proximal end of the third wall, the portion of the third wall between the slots and comprising the distal projection forming a cantilevered section of the third wall.
 10. The elastically averaged alignment system of claim 1, wherein: the first alignment feature and the third elastically deformable alignment element are disposed in an interference fit condition in a first direction; and the second alignment feature and the fourth elastically deformable alignment element are disposed in an interference fit condition in a second direction orthogonal to the first direction.
 11. The elastically averaged alignment system of claim 1, wherein: the first component comprises a first mating side; the second component comprises a second mating side; and the third elastically deformable alignment element when disposed to interferingly, deformably and matingly engage with the first alignment feature biases the first and second mating sides against each other.
 12. The elastically averaged alignment system of claim 1, wherein: the first component comprises a first set of the first and second alignment features, and a second spaced-apart set of the first and second alignment features; the second component comprises a third set of the third and fourth elastically deformable alignment elements, and a fourth spaced-apart set of the third and fourth elastically deformable alignment elements; the third set is elastically, deformably and matingly engaged with the first set; the fourth set is elastically, deformably and matingly engaged with the second set; and a biasing force present between the first and third sets opposes a biasing force present between the second and fourth sets.
 13. The elastically averaged alignment system of claim 1, wherein: the first component comprises a first portion of a fuel door; and the second component comprises a second portion of the fuel door.
 14. The elastically averaged alignment system of claim 1, wherein: the first component comprises a cover; and the second component comprises a hinge. 